Brake lining cup attachment method for reduced wear

ABSTRACT

A brake lining assembly is provided for improved useful life. A brake lining assembly may comprise a carrier disk, a brake lining cup secured to the carrier disk and filled with a brake lining material, wherein the segmented brake lining cup has a center, wherein the brake lining material is secured to the carrier disk with an attachment fastener through the lining material and the brake lining cup, and wherein the attachment fastener is offset from the center.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patent application Ser. No. 11/900,117, entitled “Brake Lining Cup Attachment Method For Reduced Wear” and filed on Sep. 10, 2007, which claims priority to U.S. Provisional Patent Application No. 60/825,273, entitled “Brake Lining Cup Attachment Method For Reduced Wear” and filed Sep. 11, 2006, all of which are hereby incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

The present invention is in the field of braking systems. More specifically, this invention relates to the brake linings for use in a braking disk. Generally, modern steel brake designs rely on the friction generated between solid steel and sintered metal wear surfaces. The steel surface may take the form of a full annular disk, or may be segmented and connected, with or without a substructure, to form a full annular disk. The sintered metal components are lower in strength, and may be applied directly to an annular disk, or segmented and mounted to an annular disk substructure or lining carrier. Segmented linings contain a number of consumable lining containers or cups which are fastened to a reusable carrier. The cups are typically stamped from steel sheet metal and are formed to hold or contain the lining material. The cups are usually plated to protect against corrosion, and to aid in developing a metallurgical bond with the lining material. Powdered metal is then added to the lining cup through the conventional process of densification and sintering. Brake wear is effected by, among other things, the ratio of energy absorbed per unit of lining surface area (lining loading). Due to the porosity of powdered metal material, linings also act as good insulators. As a result of this, energy, in the form of heat, is slow to transfer through the lining material. Large thermal gradients therefore develop through the thickness of the cup. Due to differential thermal expansion, the lining cup deforms such that the area at the wear interface is reduced. This results in a reduction in “effective” lining area, high localized lining loadings and subsequently increased wear.

In the past, the lining material was attached through the center of the lining cup. Thus when the thermal differential discussed above caused deformation, this deformation left only a wear area in the center around the attachment point. This is shown in FIGS. 2 and 3.

Accordingly, a method of attachment of the lining cups and material is desired which would increase the “effective” lining wear area, even after sustained use.

SUMMARY OF THE INVENTION

A brake lining assembly comprising an annular carrier disk and a plurality of segmented brake lining cups is provided. The segmented brake lining cups further comprise a center secured to the carrier disk and filled with brake lining material, wherein the brake lining material is secured to the carrier disk through the lining cups with an attachment fastener forming a brake lining assembly, and wherein the attachment fastener is offset from the lining cup center.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an end view of a brake lining assembly according to an aspect of the invention;

FIG. 2 is a top view of a prior art brake lining assembly;

FIG. 3 is a cross section view of FIG. 2;

FIG. 4 is a top view of a brake lining assembly according to an aspect of the invention;

FIG. 5 is a cross section view of FIG. 4, additionally showing the brake disk in relation to the brake lining assembly;

FIG. 6 is a top view of a brake lining assembly according to an aspect of the invention;

FIG. 7 is a cross section view of FIG. 6, additionally showing the brake disk in relation to the brake lining assembly;

FIG. 8 is a top view of a brake lining assembly according to an aspect of the 25 invention;

FIG. 9 is a cross section view of FIG. 8, additionally showing the brake disk in relation to the brake lining assembly;

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration and its best mode, and not of limitation. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be realized and that logical, chemical and mechanical changes may be made without departing from the spirit and scope of the invention. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Moreover, many of the functions or steps may be outsourced to or performed by one or more third parties. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact.

Various aspects of the invention are presented in FIGS. 1 and 4-9 which are not drawn to scale and in which like components are numbered alike. With reference to FIGS. 1 and 4-9 in an embodiment, according to various embodiments, a brake disk 10 is similarly engaged by a brake lining assembly 40. An annular carrier disk 12 includes a plurality of segmented brake lining cups 20 secured to the carrier disk 12. Lining cups 20 each have a center 22 and are at least partially filled with brake lining material 30. The brake lining material 30 is secured to the carrier disk 12 through the lining cups 20 with an attachment fastener 35, forming a brake lining assembly 40. The brake lining assembly 40 has a wear surface.

To overcome problems of conventional systems, according various embodiments, the attachment fastener 35 may be offset from the lining cup center 22. Various embodiments may result in an increase in wear area 31 b, lower localized lining loading and subsequently reduced wear. This is shown in FIGS. 1 and 4-9. FIGS. 1 and 4-9 show several configurations for the offset of the attachment fastener 35, however various embodiments are not limited to these particular offsets. The fasteners may be offset diagonally, tangentially, or various other ways which leave the wear area 31 b.

In an embodiment, the annular carrier disk 12 includes an inner radius 14 and an outer radius 16. The lining cups 20 have a corresponding inner edge 24 and a corresponding outer edge 26, and the attachment fastener 35 is located closer to the lining cup outer edge 26 than to the lining cup center 22, though the attachment fastener 35 may also be located generally closer to the lining cup inner edge 24 than to the lining cup center 22.

In various embodiments, two attachment fasteners 35 may be used for attachment of the lining material 30 to the carrier 12 through the lining cup 20 and may be located on opposing sides of the lining cup center 22. Alternatively, one attachment fastener 35 may be located closer to the lining cup inner edge 24 than to the lining cup center 22 and the other attachment fastener 35 may be located closer to the lining cup outer edge 26 than to the lining cup center 22.

In various embodiments, a torque button may be included in a brake disk assembly. As used herein, a torque button is a portion of the lining cup or a component attached to the lining cup that may extend into a corresponding indentation in the carrier. While the attachment fasteners 35 are intended to provide axial connection of the cups to the carrier, the torque button is intended to transfer shear loads created by the relative disk rotation.

In prior art applications, torque button were generally located in the same location as the attachment fastener 35, namely, in the lining cup center 22. However, according to an embodiment, the lining cup 20 is formed with a torque button 50 in the lining cup center 22, wherein this torque button 50 extends into the carrier disk 12. In various embodiments, with reference to FIG. 9, the torque button 50 is attached to the lining cup center 22.

According to an embodiment, a method of attachment of a brake lining cup 20 and brake lining material 30 to an annular carrier disk 12 comprises forming a lining cup 20 having a center 22 and forming lining material 30 to fit into the lining cup 20, thus having a corresponding lining material center 32. The lining material 30 has at least one attachment hole 38 offset from the lining material center 32. The method further comprises attaching the lining material 30 to the carrier 12 through the lining cup 20 with an attachment fastener 35 through the attachment hole 38.

According to an embodiment, the annular carrier disk 12 includes an inner radius 14 and an outer radius 16, and the lining material 30 includes a corresponding inner edge 34, and a corresponding outer edge 36, wherein the attachment hole 38 is located more proximate to the lining material outer edge 36 than to the lining material center 32, the attachment hole 38 may also be located more proximate to the lining material inner edge 34 than to the lining material center 32.

In an embodiment, two attachment fasteners 35 may be used for attachment of the lining material 30 to the carrier 12 through the lining cup 20, wherein the attachment holes 38 are located on opposing sides of the lining cup material center 32. In a further embodiment, one attachment hole 38 is located closer to the lining cup material inner edge 34 than to the lining cup material center 32, and the other attachment hole 38 is located closer to the lining cup material outer edge 36 than to the lining cup material center 32.

Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the invention. The scope of the invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. 

1. A brake lining assembly comprising: a carrier disk; a brake lining cup secured to said carrier disk, wherein at least a portion of said brake lining cup is filled with a brake lining material; wherein said brake lining cup has a center; wherein said brake lining material is secured to said carrier disk with an attachment fastener through said brake lining material and said brake lining cup; and, wherein said attachment fastener is offset from said center.
 2. The brake lining assembly of claim 1, wherein said brake lining cup further comprises a torque button in said brake lining cup.
 3. The brake lining assembly of claim 2, wherein said torque button is offset from said attachment fastener.
 4. The brake lining assembly of claim 2, wherein said torque button extends into said carrier disk.
 5. The brake lining assembly of claim 1, wherein said attachment fastener is configured to transfer torque.
 6. The brake lining assembly of claim 1, wherein said attachment fastener is configured so as to transfer minimal torque.
 7. The brake lining assembly of claim 1, wherein said carrier disk further comprises an inner radius and an outer radius, said brake lining cup includes an inner edge and an outer edge, and said attachment fastener is located closer to said brake lining cup outer edge than to said brake lining cup center.
 8. The brake lining assembly of claim 1, wherein said carrier disk further comprises an inner radius and an outer radius, said brake lining cup includes an inner edge and an outer edge, said attachment fastener is located closer to said brake lining cup inner edge than to said brake lining cup center.
 9. The brake lining assembly of claim 1, further comprising an additional fastener, wherein said carrier disk further comprises an inner radius and an outer radius, said brake lining cup includes an inner edge and an outer edge, and said attachment fasteners are located on opposing sides of said brake lining cup center.
 10. The brake lining assembly of claim 1, further comprising an additional fastener, wherein said carrier disk further comprises an inner radius and an outer radius, said brake lining cups include an inner edge and an outer edge, one of said attachment fastener is located closer to said brake lining cup inner edge than to said brake lining cup center, and said additional attachment fastener is located closer to said brake lining cup outer edge than to said brake lining cup center.
 11. The brake lining assembly of claim 1, wherein said brake lining cup further comprises a torque button in said brake lining cup center, wherein said torque button extends into said carrier disk.
 12. A method comprising the steps of: coupling a brake lining cup and a brake lining material, wherein said brake lining material is configured to fit into said brake lining cup, and said brake lining cup having a brake lining cup center and a brake lining material center corresponding to said brake lining cup center, wherein said brake lining material has an attachment hole offset from said brake lining material center; and attaching said brake lining material to a carrier disk through said brake lining cup with an attachment fastener through said attachment hole.
 13. The method of claim 12, wherein said brake lining cup further comprises a torque button offset from said attachment fastener.
 14. The method of claim 13, wherein said torque button extends into said carrier disk.
 15. The method of claim 12, wherein said brake lining cup further comprises a torque button in said brake lining cup center, wherein said torque button extends into said carrier disk.
 16. The attachment method of claim 12, further comprising: fabricating a torque button; attaching said torque button to said brake lining cup, wherein said torque button extends into said carrier disk.
 17. The method of claim 12, wherein said carrier disk further comprises an inner radius and an outer radius, said brake lining cup and brake lining material each have an inner edge and an outer edge, and said attachment hole is located closer to said brake lining material outer edge than to said brake lining material center.
 18. The method of claim 12, wherein said carrier disk further comprises an inner radius and an outer radius, said brake lining cup and brake lining material each have an inner edge and an outer edge, and said attachment hole is located closer to said brake lining material inner edge than to said brake lining material center.
 19. The method of claim 12, further comprising an additional fastener for attachment of said brake lining material to said carrier through said brake lining cup, wherein said carrier disk further comprises an inner radius and an outer radius, said brake lining cup and brake lining material each have an inner edge and an outer edge, and said attachment holes are located on opposing sides of said brake lining material center.
 20. The method of claim 12, further comprising an additional fastener for attachment of said brake lining material to said carrier through said brake lining cup, wherein said carrier disk further comprises an inner radius and an outer radius, said brake lining cup and said brake lining material each have an inner edge and an outer edge, and one of said attachment holes is located closer to said brake lining material inner edge than to said brake lining material center, and said other attachment hole is located closer to said brake lining material outer edge than to said brake lining material center. 